Determination of the heat transfer coefficient at the metal–die interface for high pressure die cast AlSi9Cu3Fe

When simulating the High Pressure Die Casting ‘HPDC’ process, the heat transfer coefficient ‘HTC’ between the casting and the die is critical to accurately predict the quality of the casting. To determine the HTC at the metal–die interface a production die for an automotive engine bearing beam, Die 1, was instrumented with type K thermocouples. A Magmasoft® simulation model was generated with virtual thermocouple points placed in the same location as the production die. The temperature traces from the simulation model were compared to the instrumentation results. Using the default simulation HTC for the metal–die interface, a poor correlation was seen, with the temperature response being much less for the simulation model. Because of this, the HTC at the metal–die interface was modified in order to get a better fit. After many simulation iterations, a good fit was established using a peak HTC of 42,000 W/m2 K, this modified HTC was further validated by a second instrumented production die, proving that the modified HTC gives good correlation to the instrumentation trials. The updated HTC properties for the simulation model will improve the predictive capabilities of the casting simulation software and better predict casting defects.

Study of structural change in Wyodak coal in high pressure CO2 by small-angle neutron scattering

Small angle neutron scattering (SANS) has been applied to examine the effect of high pressure CO2 on the structure of Wyodak coal. Significant decrease in the scattering intensities upon exposure of the coal to high pressure CO2 showed that high pressure CO2 rapidly adsorbs on the coal and reaches to all pores in the structure. This is confirmed by strong and steep exothermic peaks observed on DSC scans during coal/ CO2 interactions. In situ small angle neutron scattering on coal at high pressure CO2 atmosphere showed an increase in scattering intensities with time suggesting that after adsorption, high pressure CO2 immediately begins to diffuse into the coal matrix, changes the macromolecular structure of the coal, swells the matrix and probably creates microporosity in coal structure by extraction of volatile components from coal. Significant decrease in the glass transition temperature of coal caused by high pressure CO2 also confirms that CO2 at elevated pressures dissolve in the coal matrix, results in significant plasticization and physical rearrangement of the coal’s macromolecular structure.

Asymptotic layer-type model of high pressure direct current glow discharge in electronegative gases

Here a self-consistent one-dimensional continuum model is presented for a narrow gap plane-parallel dc glow discharge. The governing equations consist of continuity and momentum equations for positive and negative ions and electrons coupled with Poisson's equation. A singular perturbation method is developed for the analysis of high pressure dc glow discharge. The kinetic processes of the ionization, electron attachment, and ion-ion recombination are included in the model. Explicit results are obtained for the asymptotic limits: delta=(r(D)/L)(2)--> 0, omega=(r(S)/L)(2)--> 0, where r(D) is the Debye radius, r(S) is recombination length, and L is the gap length. The discharge gap divides naturally into four layers with multiple space scales: anode fall region, positive column, transitional region, cathode fall region and diffusion layer adjacent to the cathode surface, its formation is discussed. The effects of the gas pressure, gap spacing and dc voltage on the electrical properties of the layers and its dimension are investigated. (C) 2000 American Institute of Physics. [S0021-8979(00)00813-6].

Asymptotic modeling of short plane-parallel high-pressure glow discharge

Here a self-consistent continuum model is presented for a narrow gap plane-parallel dc glow discharge. The set of governing equations consisting of continuity and momentum equations for positive ions, fast (emitted by the cathode) and slow electrons (generated by fast electron impact ionization) coupled with Poisson's equation is treated by the technique of matched asymptotic expansions. Explicit results are obtained in the asymptotic limit: (chi delta) much less than 1, where chi = e Phi(a)/kT, delta = (r(D)/L)(2) (Phi(a) is the applied voltage, r(D) is the Debye radius) and pL much greater than 1(Hg mm cm), where p is the gas pressure and L is the gap length. In the case of high pressure, the electron energy relaxation length is much smaller than the gap length, and so the local field approximation is valid. The discharge space divides naturally into a cathode fall sheath, a quasineutral plasma region, and an anode fall sheath. The electric potential distribution obtained for each region in a (semi)analytical form is asymptotically matched to the adjoining regions in the region of overlap. The effects of the gas pressure, gap length, and applied voltage on the length of each region are investigated. (C) 2000 American Institute of Physics. [S1070-664X(00)01302-1].

Selective hydrogenation of acetylene in ethylene rich feed streams at high pressure over ligand modified Pd/TiO2

The selective hydrogenation of acetylene from ethylene rich streams was conducted at high pressure and in the presence of CO over two 1 wt% loaded Pd/TiO2 catalysts with differing dispersions. Although, the more poorly dispersed sample did not result in high acetylene conversion only a small proportion of the total available ethylene was hydrogenated to ethane. The more highly dispersed sample was able to remove acetylene to a level below the detection limit but this was at the expense of significant proportion (ca. 30%) of the available ethylene. Modification of the catalysts by exposure to triphenyl phosphine or diphenyl sulfide and subsequent reduction at 393 K led to improved performance with increased conversion of acetylene and decreased propensity to hydrogenate ethylene resulting in an overall net gain in ethylene. The higher dispersed sample which had been ligand modified provided the best results overall and in particular for the diphenyl sulfide treated sample which was able to completely eliminate acetylene and still obtain a net gain in ethylene. The differences observed are thought to be due to the creation of appropriate active ensembles of Pd atoms which are able to accommodate acetylene but have limited ability to adsorb ethylene. Sub-surface hydrogen formation was suppressed, but not eliminated, by exposure to modifier.

Predicting die life from die temperature for high pressure dies casting

The objective of this research was to determine the surface temperature of a high pressure die casting die during casting conditions. This was achieved by instrumentation of an insert which was placed in the shotplate region of the die. This research overcame the challenge of directly measuring the die surface temperature during a HPDC production casting cycle and shows that this is an effective method to determine the die surface temperature during the casting cycle. The instrumentation results gave a peak and minimum temperature of 500 C and 240 C respectively during steady state running conditions with a molten aluminium casting temperature of 660 C. Stress analysis from the steady state measured temperature of the die surface was calculated through a simple FEA model and the resulting stress uctuation was applied to a fatigue equation for the die material, the predicted number of cycles for cracking to start was found to correlate well with observed die damage.

High-pressure volumetric properties of imidazolium-based ionic liquids: Effect of the anion

The densities of five imidazolium-based ionic liquids (ILs) (1-butyl-3-methylimidazolium tetrafluoroborate, [CiC4-Im][BF 4]; 1-butyl-3-methylimidazolium hexafluorophosphate, [CiC 4Im][PF6]; 1-butyl-3-methylimidazolium bis{(trifluoromethyl)sulfonyl}imide, [C1C4Im][Tf 2N]; 1-ethyl-3-methylimidazoliumbis{(trifluoromethyl)sulfonyl}-imide, [C1C2Im][Tf2N]; l-ethyl-3-methylimidazolium ethylsulfate, [C1C2Im][EtSO4]) were measured as a function of temperature from (293 to 415) K and over an extended pressure range from (0.1 to 40) MPa using a vibratingtube densimeter. Knowledge of the variation of the density with temperature and pressure allows access to the mechanical coefficients: thermal expansion coefficient and isothermal compressibility. The effects of the anion and of the length of the alkyl chain on the imidazolium ring on the volumetric properties were particularly examined. The mechanical coefficients were compared with those of common organic solvents, water and liquid NaCl. Finally, a prediction model, based on an "ideal" volumetric behavior of the ILs, is proposed to allow calculation of the molar volume of imidazolium-based ionic liquids as a function of temperature. ©2007 American Chemical Society.

Stress correlation between instrumentation and simulation analysis of the die for high pressure die casting

A strain gauge instrumentation trial on a high pressure die casting ‘HPDC’ die was compared to a corresponding simulation model using Magmasoft® casting simulation software at two strain gauge rosette locations. The strains were measured during the casting cycle, from which the von Mises stress was determined and then compared to the simulation model. The von Mises stress from the simulation model correlated well with the findings from the instrumentation trial, showing a difference of 5.5%, ~ 10 MPa for one strain gauge rosette located in an area of low stress gradient. The second rosette was in a region of steep stress gradient, which resulted in a difference of up to 40%, ~40 MPa between the simulation and instrumentation results. Factors such as additional loading from die closure force or metal injection pressure which are not modelled by Magmasoft® were seen to have very little influence on the stress in the die, less than 7%.

Comments and Additional Work on “High-Pressure Volumetric Properties of Imidazolium-Based Ionic Liquids: Effect of the Anion”

This works follows a publication of our group in J. Chem. Eng. Data2007, 52, 2204–2211 presenting high temperature and pressure density data for five imidazolium-based ionic liquids. At this period, very few ionic liquid density data were available in the literature, especially at high pressure, and the uncertainty of published results was calculated with respect to the literature data available for three of the five ionic liquids studied. Since 2007, the ionic liquid density databank has largely increased. In this work, a comparison of our published data in J. Chem. Eng. Data2007, 52, 2204–2211, with more than 1800 high pressure data coming from the literature up to December 2011 is presented to assess the uncertainty of our published values. The claimed uncertainty is close to 0.31 % for all IL density data sets except in the case of the [C1C2Im][EtSO4], where the uncertainty is up to 1.1 %. Reported data in J. Chem. Eng. Data2007, 52, 2204–2211, for this particular ionic liquid cannot be used as a reference. For this ionic liquid, new density measurements of the same sample batch have been remeasured by using the same experimental technique, and new experimental data presented herein are clearly higher than our previous published results. A 1H NMR analysis of the sample has confirmed hydrolysis of the ethylsulfate anion to ethanol and hydrogenate anion which explains the differences observed between our density data and the literature.

Coexistence of Weak Ferromagnetism and Ferroelectricity in the High Pressure LiNbO_{3}-Type Phase of FeTiO_{3}

We report the magnetic and electrical characteristics of polycrystalline FeTiO3 synthesized at high pressure that is isostructural with acentric LiNbO3 (LBO). Piezoresponse force microscopy, optical second harmonic generation, and magnetometry demonstrate ferroelectricity at and below room temperature and weak ferromagnetism below ~120??K. These results validate symmetry-based criteria and first-principles calculations of the coexistence of ferroelectricity and weak ferromagnetism in a series of transition metal titanates crystallizing in the LBO structure.